Load Sensor System

ABSTRACT

A load sensor system including one or more of a vehicle suspension including a pair of beams outwardly extending from a vehicle axle, a pair of air suspension assemblies correspondingly coupled between the pair of beams and a vehicle frame, where each of the air suspension assemblies includes a load sensor capable of generating a load signal, a load sensor computer communicatively coupled to the load sensor having a load sensor program including a load calculator, and a central computer communicatively coupled to the load sensor computer having a central program executable to receive the load calculated by the load sensor computer.

I. FIELD OF THE INVENTION

A load sensor system including one or more load sensors disposed betweena vehicle frame and a vehicle suspension of a vehicle, each load sensorcommunicatively coupled to a computer including a load sensor programexecutable to correspondingly process one or more load signals generatedby the one or more load sensors to calculate the load disposed on theframe of the vehicle.

II. SUMMARY OF THE INVENTION

Accordingly, a broad object of particular embodiments of the inventioncan be to provide a load sensor including a load sensor body including aload sensor body first end configured to couple to a vehicle frame and aload sensor body second end configured to couple to a vehiclesuspension, the load sensor body having a load sensor which generates aload signal which varies based on the deformation of the load sensorbody in response to an amount of force transferred from the vehicleframe to the vehicle suspension.

Another broad object of the invention can be to provide a method ofmaking a load sensor including one or more of: coupling a load sensor toa load sensor body including a load sensor body first end configured tocouple to a vehicle frame (whether directly or indirectly via an airsuspension assembly or torsion member suspension assembly) and a loadsensor body second end configured to couple to a vehicle suspension, theload sensor adapted to generate a load signal which varies based on thedeformation of the load sensor body in response to an amount of forcetransferred from a vehicle frame to a vehicle suspension, and a computerincluding a processor communicatively coupled to a non-transitorycomputer readable medium containing a load sensor program executable tocorrespondingly process one or more load signals generated by the one ormore load sensors to calculate the load disposed on the frame of thevehicle.

Another broad object of the present invention can be to provide a loadsensor kit to retrofit a conventional vehicle suspension with one ormore load sensors each including a load sensor body having a first faceopposite a second face, the first face configured to affix to a vehicleair suspension assembly and the second face configured to affix to avehicle suspension, the load sensor body including a load sensor whichgenerates a load signal which varies based on the deformation of theload sensor body in response to an amount of force transferred from avehicle frame to a vehicle suspension, and a load sensor programcontained on a computer readable medium executable by a processor of acomputer to correspondingly process one or more load signals generatedby the one or more load sensors to calculate the load disposed on theframe of the vehicle.

Another broad object of the invention can be to provide a method ofusing a load sensor system including one or more of: disposing a load ona vehicle, sensing the load disposed on the vehicle by operation of oneor more load sensors coupled between the vehicle frame and the vehiclesuspension, generating a load signal from each of the load sensors, andprocessing the load signal received from each of the load sensors byoperation of a load sensor computer communicatively coupled to the loadsensor, calculating the load sensed by each load sensor by operation ofa load sensor program contained in a non-transitory computer readablemedium of the load sensor computer; transmitting calculated loadassociated with each load sensor to a client computer; processing thecalculated load associated with each load sensor by operation of theload sensor program contained in the client computer non-transitorycomputer readable memory containing the load sensor program; andcalculating the total load disposed on the vehicle frame.

Naturally, further objects of the invention are disclosed throughoutother areas of the specification, drawings, photographs, and claims.

III. BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a particular embodiment of an airsuspension assembly coupled between a vehicle frame and a vehiclesuspension.

FIG. 2 is a side elevation view of a particular embodiment of an airsuspension assembly coupled between a vehicle frame and a vehiclesuspension.

FIG. 3 is a top plan view of a particular embodiment of an airsuspension assembly.

FIG. 4 is a perspective view of a particular embodiment of an airsuspension assembly.

FIG. 5 is a bottom plan view of a particular embodiment of an airsuspension assembly.

FIG. 6 is a cross sectional view 6-6 of FIG. 3 of a particularembodiment of an air suspension assembly.

FIG. 7 is a cross sectional view 7-7 of FIG. 4 of a particularembodiment of an air suspension assembly.

FIG. 8A is a side elevation view of a particular embodiment of a loadsensor.

FIG. 8B is an enlarged view of a particular embodiment of a strainsensor.

FIG. 9 is a perspective view of a particular embodiment of an airsuspension assembly coupled to a particular embodiment of a load sensor.

FIG. 10 is a side elevation view of a particular embodiment of an airsuspension assembly coupled to a particular embodiment of a load sensor.

FIG. 11 is a top plan view of a particular embodiment of a load sensor.

FIG. 12 is a side elevation view of a particular embodiment of a loadsensor.

FIG. 13 is a bottom plan view of a particular embodiment of a loadsensor.

FIG. 14 is a cross sectional view 14-14 of a particular embodiment of aload sensor shown in FIG. 13.

FIG. 15 is a perspective view of a particular embodiment of a torsionmember coupled between a vehicle frame and a vehicle suspension.

FIG. 16 is a perspective view of a particular embodiment of a torsionmember.

FIG. 17 is a top plan view of a particular embodiment of a torsionmember.

FIG. 18 is a bottom plan view of a particular embodiment of a torsionmember.

FIG. 19 is a first end elevation view of a particular embodiment oftorsion member.

FIG. 20 is a second end elevation view of a particular embodiment of atorsion member.

FIG. 21 is a first side elevation view of a particular embodiment of atorsion member.

FIG. 22 is a second side elevation view of a particular embodiment of atorsion member.

FIG. 23 is an illustration of the forces on a particular embodiment ofan axle.

FIG. 24 is a block flow diagram of a load sensor system.

IV. DETAILED DESCRIPTION OF THE INVENTION

Generally, referring to FIGS. 1 through 24, which illustrate particularembodiments of a load sensor system (1) which can include one or moreload sensors (2) each including a load sensor body (3) including a loadsensor body first end (4) configured to couple to a vehicle frame (5) ofa vehicle (6) and a load sensor body second end (7) configured to coupleto a vehicle suspension (8) of the vehicle (6). In particularembodiments, the load sensor body first end (4) can be coupled to an airsuspension assembly (9) configured to couple to the vehicle frame (5),and the load sensor body second end (7) can be configured to couple tothe vehicle suspension (8).

For purposes of this invention, the term “vehicle” means any form of aconveyance or transport including at least one axle (10) and withoutsacrificing the breadth of the foregoing, illustrative examples ofvehicles (6) include semi-tractors, semi-tractor trailers, carriages,cars, trucks, tractors, and trailers.

For the purposes of this invention, the term “vehicle frame” means themain supporting structure, or chassis of a vehicle.

For the purposes of this invention the term “vehicle suspension” meansthe assembly linkages that connect the vehicle frame (5) to the vehiclewheels (11); and while the Figures show one particular vehiclesuspension as it relates to a single axle (10), it is to be understoodthat a vehicle (6) can include a plurality of vehicle suspensions (8)correspondingly attached to a plurality of axles (10).

Again, generally referring to FIGS. 1 through 24, embodiments of theload sensor (2) can operate to generate a load sensor signal (12) whichvaries based on an amount of force (13) transferred from the vehicleframe (5) to the vehicle suspension (8). A load sensor computer (14) canbe communicatively coupled to each of the one or more load sensors (2)to receive the load signal (12). The load sensor computer (14) caninclude a load sensor computer processor (15) communicatively coupled toa load sensor non-transitory computer readable memory (16) containing aload sensor program (17) executable to receive the load signal (12) fromthe one or more load sensors (2) and calculate the load (18) exerted bythe vehicle frame (5) to the vehicle suspension (8).

The term “load” for the purposes of this invention means the force (13)exerted from the vehicle frame (5) to the vehicle suspension (8) inNewtons or converted to any coherent system of units (such as theInternational System of Units).

Now, generally referring to FIGS. 1 and 2, and 9 and 10, a particularembodiment of the vehicle suspension (8) includes, in opposed pairs: asuspension hanger (19), a suspension main body (20) having an axleaperture element (21), and a suspension beam (22). Each suspensionhanger (19) can be coupled to the vehicle frame (5) (shown in brokenline in the example of FIG. 1). Each suspension main body (20) pivotallycouples having pivot center (PC) to one suspension hanger (19) andincludes an axle aperture element (21) communicating between asuspension main body first side (23) and a suspension main body secondside (24). Each suspension beam (22) outwardly extends from a suspensionmain body (20). An axle (10) having axle center (AC) can be disposed inthe axle aperture elements (21) of the pair of suspension main bodies(20). A first of the opposed pairs of the vehicle suspension (8) can bedisposed proximate the axle first end (25), and a second of the opposedpairs of vehicle suspension (8) can be disposed proximate an axle secondend (26). An air suspension assembly (9) can be coupled between each ofthe suspension beams (22) and the vehicle frame (5).

Now, referring primarily to FIGS. 1 through 8, there is illustrated aparticular embodiment of a load sensor (2) adapted to the particularembodiment of the vehicle suspension shown in FIGS. 1 and 2, the loadsensor (2) including a load sensor body first end (4) configured tocouple to a vehicle frame (5) and a load sensor body second end (7)configured to couple to a vehicle suspension (8) of a vehicle (6).However; other embodiments are expressly contemplated.

With reference to FIGS. 6 through 8, in particular embodiments, the loadsensor body (3) can be configured as a generally cylindrical member (27)having a load sensor body length (28) disposed between a load sensorbody first end (4) opposite a load sensor body second end (7) eachdefining a generally circular load body end surface (29). The loadsensor body first end (4) can be configured to couple to a vehicle frame(5) and the load sensor body second end (7) can be configured to coupleto the vehicle suspension (8), thereby transferring the load (18)exerted by the vehicle frame (5) to the load sensor body first end (4)through the load sensor body (3) to the load sensor body second end (7)coupled to the vehicle suspension (8). In particular embodiments, afirst fastener element (30) coupled to the load sensor body first end(4) can be configured to fasten the load sensor body first end (4) tothe vehicle frame (5), and a second fastener element (31) coupled to theload sensor body second end (7) can be configured to fasten the loadsensor body second end (7) to a vehicle suspension (8).

In the particular example of FIGS. 1 through 8, a first fastener element(30) can extend from the load sensor body first end (4) to the vehicleframe (5) and the second fastener element (31) can extend from the loadsensor body second end (7) to the vehicle suspension (8). However, thisillustrative example of first and second fastener elements (30)(31) isnot intended to preclude other configurations of fasteners useful incoupling the load sensor (2) to the vehicle frame (5) or the vehiclesuspension (8), such as, threaded bores (32) in the load sensor bodyfirst or second ends (4)(7) which rotationally receive mated threadedmembers (33).

Now, referring primarily to FIG. 6, a strain sensor (34) may be disposedon the load sensor body (3). The strain sensor (34) can be responsive toelastic deformation of the load sensor body (3) due to force (13) from aload (18) transferred from the vehicle frame (5) to the load sensor bodyfirst end (4) to generate a load signal (12) which correspondinglyvaries based upon the amount of deformation of the load sensor body (3).Examples of strain sensors (34) which can be disposed on the load sensorbody (3) include strain gauges and piezoelectric sensors; although othermechanical, hydraulic, electrical or optical sensors which respond todeformation of the load sensor body (3) can be used (referred to hereinindividually and collectively as “strain sensors”).

By way of a first example, the strain sensor (34) can, but need notnecessarily, be a transducer with a bridge circuit. The strain sensor(34) can be responsive to elastic deformation of the load sensor body(3) which can be first converted to a change in resistance, so that abridge circuit electrical output (35) can be generated and converted toa proportional output voltage (36) with the aid of an amplifier (37).

By way of a second example, the strain sensor (34) can be apiezoelectric sensor (38). The piezoelectric sensor (38) can include apiezoelectric crystal (39) (or piezo ceramic) with two parallel faces(40)(41). The first parallel face (40) can be engaged to the load sensorbody (3). Each of the two parallel faces (40)(41) can have electrodes(42) affixed thereto. The electrodes (42) can be further attached tocontacts (43) which are communicatively coupled to an external circuit(44) which can measure the change in voltage (36) of the piezoelectriccrystal (39). As the load sensor body (3) deforms under the force (13)of a load (18) transferred from the vehicle frame (5) to the vehiclesuspension (8), the piezoelectric crystal (39) can correspondinglydeform. The deformation of the piezoelectric crystal (39) generates asmall voltage (36) between the two parallel faces (40)(41). The voltage(36) generated by the deformation of the piezoelectric crystal (39) isdirectly proportional to the strain (45) generated in the load sensorbody (3) by the force (13) of a load (18) transferred from the vehicleframe (5) to the vehicle suspension (8). Thus, the change in voltage(36) directly corresponds to the change in strain (45) of thepiezoelectric crystal (39) which directly corresponds to the load (18)on the load sensor body (3).

Again, referring primarily to FIGS. 1 through 8, particular embodimentsof a load sensor system (1) can include an air suspension assembly (9)having an air suspension center (ASC). The air suspension assembly (9)can be disposed between the vehicle frame (5) and the suspension beam(22) of the vehicle suspension (8). Embodiments of the air suspensionassembly (9) can include a tubular elastomeric member (46) sealablycoupled between a first end mount (47) configured to affix to thevehicle frame (5) and a second end mount (48) coupled or engaged to theload sensor body first end (4) and having the load sensor body secondend (7) configured to affix to the vehicle suspension (8). A compressor(49) can be fluidicly coupled to the tubular elastomeric member interiorspace (50) defined by the tubular elastomeric member (46) sealablycoupled to the first and second end mounts (47)(48).

Now, referring primarily to FIGS. 3 through 8, embodiments of thetubular elastomeric member (46) sealably joined to the first end mount(47) and the second end mount (48) can provide a substantially air-tightconstruction which can receive a fluid flow (51) by operation of thecompressor (49) to maintain a pre-selected fluid pressure (52) withinthe interior space (50). The tubular elastomeric member interior space(50) can be fillable with a fluid (53). The fluid (53) can comprise orbe selected from the group consisting of: a mixture of gases, air, apurified gas, nitrogen, argon, or combinations thereof.

In particular embodiments, the first and second end mounts (47)(48) canbe configured as closed end cylinders (54)(55) and the tubularelastomeric member first and second ends (56)(57) can sealably engagethe respective cylindrical sidewalls (58) of the closed end cylinders(54)(55), similar to the construction of a Firestone Airide Air SpringW02-358-7017.

With primary reference to FIG. 6, embodiments can, but need notnecessarily, include a first end mount (47) having a mount peripheralmargin (59) mated with the tubular elastomeric member first end margin(60) and rolled to crimp the tubular elastomeric member first end margin(60) between the opposed surfaces of the rolled mount peripheral margin(59). The second end mount (48) can be configured as a tubular housing(61) with a first closed end (62) having a first face (63) inwardlyfacing the tubular elastomeric member interior space (50) and having asecond face (64) outwardly facing from the interior space (50) andengaged to the load sensor body first end (4). The load sensor body (3)extends outward from the second face (64) of the first closed end (62)and passes through a housing aperture (65) in the second closed end (66)of the tubular housing (61) to dispose the load sensor body second end(7) external to the tubular housing (61).

The tubular elastomeric member second end (57) can be circumferentiallyaffixed to the tubular housing (61).

Again, referring primarily to FIGS. 1 through 8, the first end mount(47) can include one or more fastener elements (67) configured to allowthe first end mount (47) to affix to the vehicle frame (5). While theparticular embodiments shown in the Figures show outwardly extendingthreaded members (33) which engage mateably threaded annular members(68), this illustrative example is not intended to preclude embodimentswhich employ other configurations of fastener elements (67), such asthreaded bores (32) which engage mateably threaded members (33),interlocking plates, or the like.

Similarly, the load sensor body second end (7) can include one or morefastener elements (67) configured to allow the load sensor body secondend (7) to affix to the vehicle suspension (8) (or suspension beam (22)as shown in the example of FIGS. 1 and 2). Again, while the particularembodiments shown in the Figures show an outwardly extending threadedmember (33) which engages a mateably threaded annular member (68), thisillustrative example is not intended to preclude embodiments whichemploy other configurations of fastener elements (67), such as athreaded bore (32) disposed in the load sensor body second end (7) whichmateably engage thread members (33), or the like.

Now, referring primarily to FIGS. 1 through 6, particular embodiments ofthe air suspension assembly (9) can further include a valve (69). Thevalve (69) can be coupled to the first end mount (47) or the second endmount (48). The valve (69) can be operable to allow passage of the fluid(53) into or away from the tubular elastomeric member interior space(50).

Again, referring primarily to FIGS. 1 through 6, particular embodimentsof the air suspension assembly (9) can further include a fluid pressuresensor (70). The fluid pressure sensor (70) can be coupled to the firstend mount (47) or the second end mount (48). The fluid pressure sensor(70) can generate a fluid pressure signal (71) which varies based uponthe fluid pressure (52) inside of the elastomeric member interior space(50).

In particular embodiments, a load sensor computer (14) can, but need notnecessarily, be disposed in the tubular housing (61) of the second endmount (48) of the load sensor (2). The load sensor computer (14) caninclude a load sensor computer processor (15) in communication with aload sensor computer non-transitory computer readable medium (16)containing the load sensor program (17). The load sensor computer (14)can be in the form of a microprocessor (75) disposed on a printedcircuit board (76) disposed inside of the tubular housing (61) as shownin the example of FIG. 7; although this illustrative example is notintended to preclude embodiments in which the load sensor computer (14)comprises other forms of a processor (15) and non-transitory computerreadable medium (16) or has a location outside of the tubular housing(61).

The load sensor computer (14) can be communicatively coupled to thestrain sensor (34) disposed on the load sensor body (3). The load sensorprogram (17) can include a load calculator (77) which can be executed toreceive the load sensor signal (12) generated by the load sensor (2) andcompare one or more characteristics of the load sensor signal (12)(suchas signal amplitude) against a plurality of standardized load forcevalues (78) held in a load force table (79) and correlate the loadsensor signal (12) to one or more load force values (78) which can beused to calculate the total force (80) in Newtons acting on the vehicletire (81) (shown in broken line in the examples of FIGS. 1 and 2)correspondingly associated with the load sensor (2) generating the loadsensor signal (12).

In particular embodiments the load sensor computer (14) can, but neednot necessarily, include a fluid pressure sensor module (82) executableto receive the fluid pressure signal (71) from the fluid pressure sensor(70). The fluid pressure sensor module (82) can be further executed tocompare one or more characteristics of the pressure sensor signal(71)(such as signal amplitude) against a plurality of standardized loadforce values (78) held in the load force table (79) and correlate thefluid pressure signal (12) with one or more load force values (78) whichcan be used to calculate the total force (80) in Newtons acting on thevehicle tire (81) (shown in broken line in the examples of FIGS. 1 and2) correspondingly associated with the pressure sensor (70) generatingthe pressure sensor signal (71). In particular embodiments, the loadcalculator can use the load force values (78) derived by correlation ofthe load sensor signal (12) with a standardized load force value (78),or by correlation of the fluid pressure signal (71) with a standardizedload force value (78), independent of the other, or in factoredcombination, to derive the total force (80) acting on the vehicletire(s) (81) which can be converted to any coherent system of units(such as the International System of Units).

In particular embodiments, the load sensor computer (14) can, but neednot necessarily, include a data exchanger (83) operable to transmit thecalculated total force (80) acting on the corresponding tire (81) to acentral computer (84) which can, but need not necessarily, becommunicatively coupled through a network (85) to one or more servercomputers (86)(as shown in the example of FIG. 23). In particularembodiments, the data exchanger (83) can include a radio frequencycontroller (87) which operates a radio frequency transmitter (88) tocause wireless connection or pairing of the load sensor computer (14)with the client computer (84) over a short-range radio frequency band(89) to carry a signal over all or a part of the communication pathbetween each load sensor computer (14) and the client computer (84). Theshort-range radio frequency band (89) can include, as illustrativeexamples: BLUETOOTH® (90) which operates at frequencies of about 2402MHz to about 2480 MHz or about 2400 MHz to about 243.5 MHz or WI-Fl®(91) which operates at about 2.4 GHz or 5 GHz.

Now referring generally to FIGS. 1 through 8 and 24, the load sensorsystem (1) can include a plurality of load sensors (2) each disposed tosense a load (18) transferred from the vehicle frame (5) to the vehiclesuspension (8). In particular embodiments, the load sensor system (1)can include a plurality of air suspension assemblies (9), each or aportion of the plurality of air suspension assemblies (9) can include aload sensor (2) which can be communicatively coupled to a load sensorcomputer (14) or directly to a client computer (84).

Now referring primarily to FIG. 24, the central computer (84) caninclude a central computer processor (93) communicatively coupled to acentral computer non-transitory computer readable medium (94) containinga central computer program (95). The central computer program (95) caninclude a central computer data exchanger (96) which pairs with each ofthe one or more load sensor computers (14) over the short-range radiofrequency band (89) to receive the load sensor signal (12) directly orreceive the force (13) or load data (97) calculated by the one or moreload sensor computer(s) (14). The central computer program (95) can befurther executed to calculate the total load (18) transmitted from thevehicle frame (5) to the plurality of tires (81) on the vehicle (6).

Now referring to FIGS. 1, 23, and 24, in particular embodiments, theload data received from each of the load sensor bodies can be used todetermine the total force acting on the vehicle. The force acting on thetire (81) equals the force acting on the pivot center (PC) and the forceacting on the air suspension center (ASC) (F_(t)=F_(p)+F_(a)). Thesystem can be considered to be at static equilibrium, therefore themoments are equal with regards to the moments corresponding to eachforce disposed on opposite sides of the axle. Moment is defined as forcetimes distance, so F_(p)* D₁=F_(a)* D₂ in this exemplary calculation.The foregoing equation can be solved for F_(p), because F_(a) ismeasured as indicated herein with the strain sensor (34) disposed on theload sensor body (3), and the distances are known. The total load on thetire (81) (F_(t)) can then be calculated. To calculate the total load(13) placed on the vehicle (6), each F_(t) corresponding to a pluralityof tires (81) can be summed. In further particular embodiments, thepercentage of weight of the load on each tire can further be used todetermine the load center of gravity (L_(c)). The load center of gravity(L_(c)) can be used to properly place a load (18) on the vehicle (6).

Now referring primarily to FIGS. 9 through 14, a numerous and widevariety of conventional air suspension assemblies (9) which do notcontain a load sensor body (3) can be retrofit with a load sensorretrofit kit (98) (also referred to as the “kit”). The kit (98) caninclude a load sensor body (3) configured to be positioned between aconventional air suspension assembly (9) and the vehicle frame (5) orthe vehicle suspension (8). Referring primarily to FIGS. 11 through 14,the load sensor body (3) can have a load sensor body first face (99)opposite a load sensor body second face (100). The load sensor bodyfirst face (99) can be configured to affix to the conventional airsuspension assembly (9) and the load sensor body second face (100) canbe configured to affix to a vehicle suspension (8) (as shown in theexamples of FIGS. 9 and 10). In the illustrative example of FIGS. 9 and10, the load sensor body second face (100) can be configured to beaffixed to the suspension beam (22) of the vehicle suspension (8).

Now referring primarily to FIGS. 11 through 14, in particularembodiments, the load sensor body (3) configured to retrofitconventional air suspension assemblies (9) can include a generally flatload sensor body first face (99) opposite a generally flat load sensorbody second face (100) joined a distance apart at a generally circularload sensor body perimeter (101). However, this illustrative example isnot intended to preclude embodiments having a load sensor body firstface (99) having a configuration other than generally flat to allowmated engagement with the surface of an air suspension assembly (9), andcorrespondingly is not intended to preclude embodiments having a loadsensor body second face (100) having a configuration other thangenerally flat to allow mated engagement with the surface of the vehiclesuspension (8), and correspondingly is not intended to preclude aconfiguration other than a generally circular load sensor body perimeter(10) to allow the load sensor body perimeter (10) to generallycorrespond to the contour of the air suspension assembly perimeter(102).

Again, referring primarily to FIGS. 11 through 14, the load sensor body(3) can further include one or a plurality of elongated slots (103) openat the load sensor body first face (99) and the load sensor body secondface (100). In particular embodiments, a plurality of elongate slots(103) can be circumferentially arranged (in the illustrative example ofFIG. 11 in a quadrilateral) about the center (104) of the load sensorbody (3); although, in particular embodiments, the plurality of elongateslots (103) can extend radially outward proximate the center (104) ofthe load sensor body (3) A strain sensor (34) can be disposed proximatethe elongate slot first end (105) or elongate slot second end (106) ofeach of the one or the plurality of elongated slots (103). The strainsensor (34) can generate a load signal (12) which varies based on theamount of deformation (also referred to as “strain” (45)) in or of theload sensor body (3) to the applied load (18).

As above described, the strain sensor (34) can comprise as illustrativeexamples a foil strain gauge arranged in a wheatstone bridge comprisinga simple circuit for measuring an unknown resistance by connecting theunknown resistance to a quadrilateral with three known resistances andapplying a voltage between a pair of opposite corners, or apiezoelectric crystal (39) or piezoelectric ceramic.

Again, referring primarily to FIGS. 9 through 14, in further particularembodiments, the load sensor body (3) can further include an apertureelement (107) centrally disposed in the load sensor body (3). Theaperture element (107) can permit a fastening member (108) to transversethe load sensor body (3) to affix the load sensor body (3) between theair suspension assembly (9) and the vehicle suspension (8). Inparticular embodiments, a fastening member (108) can extend from the airsuspension assembly (9), through the aperture element (107) in the loadsensor body (3), and into a fastener receiving element (109) disposed onthe vehicle suspension (8). In particular embodiments, the fastenerreceiving element (109) can be disposed on the suspension beam (22) ofthe vehicle suspension (8); however this illustrative example is notintended to preclude other fastener configurations suitable to affix theload sensor body (3) between the air suspension assembly (9) and thevehicle suspension (8), such as a threaded bore (32) disposed in the airsuspension assembly (9) and a threaded member (33) which passes througha fastener receiving element (109) of the vehicle suspension (8) androtatingly engages the threaded bore (32).

Again, referring primarily to FIGS. 9 through 14, in further particularembodiments, the load sensor body (3) can include a plurality ofaperture elements (107) disposed in spaced apart relation proximate theload sensor periphery (110). A plurality of fastener elements (67) canextend from the air suspension assembly (9), through a correspondingplurality of aperture elements (107), to affix the load sensor body (3)to the air suspension assembly (9), or into a corresponding plurality offastener receiving elements (109) disposed on the vehicle suspension(8). In particular embodiments, the fastener receiving elements (109)can be disposed on the suspension beam (22) of the vehicle suspension(8).

In particular embodiments, the configuration of the load sensor body (3)shown in FIGS. 11 through 14, can, but need not necessarily be,retrofitted to conventional air suspension assemblies (9), but rathercan be included as an integral part of an air suspension assembly (9)including a load sensor (2) which can be fitted between the vehicleframe (5) and the vehicle suspension (8).

Embodiments of the load sensor (2) shown in FIGS. 9 through 14 can becommunicatively coupled (whether wired or wirelessly) to the load sensorcomputer (14) or the client computer (84) containing the load sensorprogram (17) including the load calculator (77) which can be executed toreceive the load sensor signal (12) generated by the load sensor (2) andcalculate the total force (80) in Newtons acting on the vehicle tire(81).

Now referring primarily to FIGS. 15 through 22, in particularembodiments, the vehicle suspension (8) can include or further include aleaf-spring suspension (111) (as shown in the example of FIG. 15).Particular embodiments of the load sensor system (1) utilized with aleaf-spring suspension (111) can include one or a plurality of torsionmembers (112). The torsion members (112) can be coupled or responsive tothe leaf-spring suspension (111) (as shown in the illustrative exampleof FIG. 15). The torsion member (112) can have a torsion member firstend (113) and a torsion member second end (114). The torsion memberfirst end (113) can be fixedly coupled to vehicle frame (5). The torsionmember second end (114) can be rotationally coupled to the vehicle axle(10). A strain sensor (34) can be disposed on the torsion member (112).Typically, the strain sensor (34) can be comprise a strain gauge, or apiezoelectric crystal (39) or piezoelectric ceramic. The strain sensor(34) can generate a load sensor signal (12) which varies based on anamount of deformation of or in the torsion member (112) in response toan amount of force (13) transferred from the vehicle frame (5) throughthe torsion member (112) to the vehicle axle (10). Typically, the loadsensor (2) can be disposed on the torsion member (112) proximate thetorsion member first end (113). In response to a load (18) placed on thevehicle frame (5), the leaf-spring suspension (111) can deform inresponse to the force (13) transferred from the load (18) placed on thevehicle frame (5) to the leaf-spring suspension (111). The deformationof the leaf-spring suspension (111) results in corresponding movement ofthe axle (10) of the vehicle (6). The movement of the vehicle axle (10)in relation to the vehicle frame (5) can deform the torsion member(112). The deformation of the torsion member (112) can be sensed by thestrain sensor (34) disposed on the torsion member (112). The strainsensor (34) correspondingly generates a load sensor signal (12).Embodiments of the load sensor (2) shown in FIGS. 15 through 22 can becommunicatively coupled (whether wired or wirelessly) to the load sensorcomputer (14) or the client computer (84) containing the load sensorprogram (17) including the load calculator (77) which can be executed toreceive the load sensor signal (12) generated by the load sensor (2) andcalculate the total force (80) in Newtons acting on the vehicle tire(81).

Now referring primarily to FIG. 24, a load sensor system (1) (alsoreferred to as the “system”) can be distributed on one or more servers(115) operably coupled to one or more client computing devices (116) bya public network (85), such as the Internet (117), a cellular-basedwireless network(s) (118), or a local network) (individually orcollectively the “network”). The client computing device (116) caninclude as illustrative examples: desktop computer devices, and mobilecomputer devices such as personal computers, slate computers, tablet orpad computers, cellular telephones, personal digital assistants,smartphones, programmable consumer electronics, or combinations thereof.The network (85) supports a load sensor program (17) (also referred toas the “program”) accessible by browser based on-line processing ordownloadable by the client computing devices (116) to enable clientcomputing devices (116) to establish off-line wired or wirelessconnection with one or more load sensors (2) operable to sense a load(18) transferred from the vehicle frame (5) through the vehiclesuspension (8) to a vehicle tire (81) and to provide the load sensorprogram (17) including a load calculator (77) operable by the clientcomputing device (116) to receive load sensor data (97) or calculatedload force (13) from each load sensor (2) and to further calculate thetotal load (18) exerted on the vehicle frame (5).

Again, referring generally to FIGS. 1 through 24, particular methods ofusing a load sensor system (1) can further include one or more of:disposing a load (18) on a vehicle (6), sensing the load (18) disposedon the vehicle by operation of one or more load sensors (2) coupledbetween the vehicle frame (5) and the vehicle suspension (8), generatinga load signal (12) from each load sensor (2), and processing the loadsignal (12) received from each load sensor (2) by operation of a loadsensor computer (14) communicatively coupled to the load sensor (2),calculating the load (18) sensed by each load sensor (2) by operation ofa load sensor program (17) contained in a load sensor computernon-transitory computer readable medium (16); transmitting calculatedload (18) associated with each load sensor (2) to a central computer(84); processing the calculated load (18) associated with each loadsensor (2) by operation of the load sensor program (17) contained in thecentral computer non-transitory computer readable memory (94) containingthe load sensor program (17); and calculating the total load (18)disposed on the vehicle frame (5).

As can be easily understood from the foregoing, the basic concepts ofthe present invention may be embodied in a variety of ways. Theinvention involves numerous and varied embodiments of a load sensorysystem and methods for making and using such load sensor systemincluding the best mode.

As such, the particular embodiments or elements of the inventiondisclosed by the description or shown in the figures or tablesaccompanying this application are not intended to be limiting, butrather exemplary of the numerous and varied embodiments genericallyencompassed by the invention or equivalents encompassed with respect toany particular element thereof. In addition, the specific description ofa single embodiment or element of the invention may not explicitlydescribe all embodiments or elements possible; many alternatives areimplicitly disclosed by the description and figures.

It should be understood that each element of an apparatus or each stepof a method may be described by an apparatus term or method term. Suchterms can be substituted where desired to make explicit the implicitlybroad coverage to which this invention is entitled. As but one example,it should be understood that all steps of a method may be disclosed asan action, a means for taking that action, or as an element which causesthat action. Similarly, each element of an apparatus may be disclosed asthe physical element or the action which that physical elementfacilitates. As but one example, the disclosure of a “signal” should beunderstood to encompass disclosure of the act of “signaling”—whetherexplicitly discussed or not—and, conversely, were there effectivelydisclosure of the act of “signaling”, such a disclosure should beunderstood to encompass disclosure of a “signal” or even a “means forsignaling.” Such alternative terms for each element or step are to beunderstood to be explicitly included in the description.

In addition, as to each term used, it should be understood that unlessits utilization in this application is inconsistent with suchinterpretation, common dictionary definitions should be understood to beincluded in the description for each term as contained in the RandomHouse Webster's Unabridged Dictionary, second edition, each definitionhereby incorporated by reference.

All numeric values herein are assumed to be modified by the term“about”, whether or not explicitly indicated. For the purposes of thepresent invention, ranges may be expressed as from “about” oneparticular value to “about” another particular value. When such a rangeis expressed, another embodiment includes from the one particular valueto the other particular value. The recitation of numerical ranges byendpoints includes all the numeric values subsumed within that range. Anumerical range of one to five includes for example the numeric values1, 1.5, 2, 2.75, 3, 3.80, 4, 5, and so forth. It will be furtherunderstood that the endpoints of each of the ranges are significant bothin relation to the other endpoint, and independently of the otherendpoint. When a value is expressed as an approximation by use of theantecedent “about,” it will be understood that the particular valueforms another embodiment. The term “about” generally refers to a rangeof numeric values that one of skill in the art would consider equivalentto the recited numeric value or having the same function or result.Similarly, the antecedent “substantially” means largely, but not wholly,the same form, manner or degree and the particular element will have arange of configurations as a person of ordinary skill in the art wouldconsider as having the same function or result. When a particularelement is expressed as an approximation by use of the antecedent“substantially,” it will be understood that the particular element formsanother embodiment.

Moreover, for the purposes of the present invention, the term “a” or“an” entity refers to one or more of that entity unless otherwiselimited. As such, the terms “a” or “an”, “one or more” and “at leastone” can be used interchangeably herein.

Thus, the applicant(s) should be understood to claim at least: i) eachof the load sensor systems herein disclosed and described, ii) therelated methods disclosed and described, iii) similar, equivalent, andeven implicit variations of each of these devices and methods, iv) thosealternative embodiments which accomplish each of the functions shown,disclosed, or described, v) those alternative designs and methods whichaccomplish each of the functions shown as are implicit to accomplishthat which is disclosed and described, vi) each feature, component, andstep shown as separate and independent inventions, vii) the applicationsenhanced by the various systems or components disclosed, viii) theresulting products produced by such systems or components, ix) methodsand apparatuses substantially as described hereinbefore and withreference to any of the accompanying examples, x) the variouscombinations and permutations of each of the previous elementsdisclosed.

The background section of this patent application provides a statementof the field of endeavor to which the invention pertains. This sectionmay also incorporate or contain paraphrasing of certain United Statespatents, patent applications, publications, or subject matter of theclaimed invention useful in relating information, problems, or concernsabout the state of technology to which the invention is drawn toward. Itis not intended that any United States patent, patent application,publication, statement or other information cited or incorporated hereinbe interpreted, construed or deemed to be admitted as prior art withrespect to the invention.

The claims set forth in this specification, if any, are herebyincorporated by reference as part of this description of the invention,and the applicant expressly reserves the right to use all of or aportion of such incorporated content of such claims as additionaldescription to support any of or all of the claims or any element orcomponent thereof, and the applicant further expressly reserves theright to move any portion of or all of the incorporated content of suchclaims or any element or component thereof from the description into theclaims or vice-versa as necessary to define the matter for whichprotection is sought by this application or by any subsequentapplication or continuation, division, or continuation-in-partapplication thereof, or to obtain any benefit of, reduction in feespursuant to, or to comply with the patent laws, rules, or regulations ofany country or treaty, and such content incorporated by reference shallsurvive during the entire pendency of this application including anysubsequent continuation, division, or continuation-in-part applicationthereof or any reissue or extension thereon.

Additionally, the claims set forth in this specification, if any, arefurther intended to describe the metes and bounds of a limited number ofthe preferred embodiments of the invention and are not to be construedas the broadest embodiment of the invention or a complete listing ofembodiments of the invention that may be claimed. The applicant does notwaive any right to develop further claims based upon the description setforth above as a part of any continuation, division, orcontinuation-in-part, or similar application.

1. A load sensor, comprising: a load sensor body having a load sensorbody first end configured to couple to a vehicle frame and a load sensorbody second end configured to couple to a vehicle suspension; and aforce measurement sensor disposed on said load sensor body, said forcemeasurement sensor generating a load signal which varies based on anamount of force transferred from said vehicle frame to said vehiclesuspension.
 2. The load sensor of claim 1, further comprising an airsuspension assembly disposed between said vehicle frame and said loadsensor body first end, wherein said load sensor body first endconfigured to couple to said air suspension assembly.
 3. The load sensorof claim 2, wherein said air suspension assembly comprises a tubularelastomeric member sealably joined to a first end mounting plateaffixable to said vehicle frame and a second end mounting plate affixedto said load sensor body first end, said load sensor body second endaffixable to said vehicle suspension.
 4. The load sensor of claim 3,wherein said tubular elastomeric member sealably joined to said firstend mounting plate and to said second end mounting plate defines anelastomeric member interior space finable with a fluid.
 5. The loadsensor of claim 4, wherein said fluid is selected from the groupconsisting of: a mixture of gases, air, a purified gas, nitrogen, andargon, or combinations thereof.
 6. The load sensor of claim 4, furthercomprising a valve coupled to said first or second end mounting plate,said valve operable to allow passage of said fluid into or away fromsaid elastomeric member interior space.
 7. The load sensor of claim 6,further comprising a fluid pressure sensor coupled to said first orsecond end mounting plate, said fluid pressure sensor generates a fluidpressure signal which varies based upon fluid pressure inside of saidelastomeric member interior space.
 8. The load sensor of claim 4,wherein said vehicle suspension includes a beam extending from a vehicleaxle, said second end mounting plate configured to affix to said beam ofsaid vehicle suspension.
 9. The load sensor of claim 1, furthercomprising a processor communicatively coupled to a non-transitorymemory element containing a load sensor program including: a loadcalculator executable to receive said load signal generated by saidforce measurement sensor coupled to said load sensor body; and calculatea load exerted from said vehicle frame to said vehicle suspension basedon said load signal generated by said force measurement sensor.
 10. Theload sensor of claim 9, further comprising a transceiver operable bysaid load sensor program to transmit said load calculated by said loadcalculator to a central computer.
 11. The load sensor of claim 3,further comprising a tubular housing affixed to said second end mountingplate to annularly surround said load sensor body, said load sensor bodysecond end extending outward of said tubular housing.
 12. The loadsensor of claim 10, wherein said load calculator has a location insideof said tubular housing.
 13. The load sensor of claim 12, wherein saidtransceiver has a location inside of said tubular housing. 14-62.(canceled)
 63. The load sensor of claim 3, further comprising aprocessor communicatively coupled to a non-transitory memory elementcontaining a load sensor program including: a load calculator executableto receive said load signal generated by said force measurement sensorcoupled to said load sensor body; and calculate a load exerted from saidvehicle frame to said vehicle suspension based on said load signalgenerated by said force measurement sensor.
 64. The load sensor of claim63, further comprising a transceiver operable by said load sensorprogram to transmit said load calculated by said load calculator to acentral computer.
 65. The load sensor of claim 64, wherein said loadcalculator has a location inside of said tubular housing.
 66. The loadsensor of claim 65, wherein said transceiver has a location inside ofsaid tubular housing.